Rail-less roof mounting system

ABSTRACT

A rail-less roof mounting system for installing photovoltaic (PV) modules on a roof structure comprises a base mount assembly that engages with a clamp assembly and attaches to the roof structure. The base mount assembly comprises a base member having a waterproof means, a block slider, a top slider and a covering means. An elevated seal portion of a block slider includes a borehole to receive the waterproof means. A vertical engaging portion of the block slider is attached with a sliding seal member of the top slider. The clamp assembly includes a clamp member and a plate member and the clamp member is attached with a track of the top slider. The clamp member interlocks the PV modules to provide a corner-to-corner coupling arrangement, which enables the connection of PV module corners to adjacent PV module corners by sandwiching above and beneath frame members of the PV modules.

RELATED APPLICATIONS

This application claims is a continuation of U.S. nonprovisionalapplication with Ser. No. 15/045,434 filed on Feb. 17, 2016, which is acontinuation of U.S. nonprovisional application with Ser. No. 14/605,368filed on Jan. 26, 2015, which is a continuation of U.S. nonprovisionalapplication with Ser. No. 14/166,633 filed on Jan. 28, 2014, now grantedas U.S. Pat. No. 8,938,932 and which claims the benefit of provisionalpatent application with Ser. No. 61/916,046.

BACKGROUND OF THE DISCLOSURE

Technical Field of the Disclosure

The present embodiment relates in general to mounting systems forphotovoltaic (PV) modules on roof structures. More specifically, thepresent disclosure relates to a rail-less photovoltaic (PV) modulemounting system for providing a cost-effective means to install aplurality of photovoltaic (PV) modules on a roof structure.

Description of the Related Art

With the increased use of photovoltaic (PV) roofing systems forgenerating electricity, a demand for mounting hardware, which attachesframes for the purpose of installing the PV modules to the roofstructure or any other support structure, has been developed. In recentyears, various kinds of mounting structures have been used which allowthe installation of PV modules to the roof structures. Mountingstructures come in a variety of sizes and patterns to meet installationpurposes. However, most of the mounting structures require increasedlabor time and cost for installation of the PV modules on the roofstructures.

Conventional mounting structures for supporting PV modules in frameshave considerable drawbacks. For example, many mounting structuresutilize rails to mount the PV modules to the roof structure to form a PVarray. The use of these rails requires additional materials to supportthe PV modules. Because of use of the additional material, thesetraditional mounting structures can result in excess shipping costs.They can also limit the PV array layout possibilities and dramaticallyincrease the time for designing, engineering and installing the mountingstructures. Existing devices are expensive, difficult to use and canrequire additional manpower to install. For example, a typical 5 kW PVmounting system designed to mount 20 PV panels (15.37% efficient)mounted on a traditional rail mounting system requires approximately 302parts at a total cost of $0.69/W retail for the mounting structure onlyand weighs over 300 Lbs. Typical installation times for a simple 4×5 (4rows and 5 columns) PV module rail based mounting system areapproximately 49 man-hours.

Traditional rail mounting systems require 5 penetrations per mount, 4mounts per PV module, additional grounding lugs, and requiresspecifically engineered PV modules. In addition, existing rail mountingsystems may have substandard waterproofing for roof penetrations, alongwith complex grounding, wire management, and increased labor time on theroof structure due to design flaws. Hard and soft balance of system(BOS) may include bypass diodes, blocking diodes, solar controller,wiring system, battery and/or inverter etc. The hard and soft balance ofsystem (BOS) costs for PV rail mounting system are high due to highmaterial costs as well as long system engineering and installationtimes. Also, the traditional rail mounting systems require long stringsthat are difficult to break up, causing difficulty in working aroundroof obstructions (e.g. vents, skylights).

One of the existing mounting systems describes an integrated moduleframe and racking system for a solar panel. The system comprises aplurality of solar modules and a plurality of splices for coupling theplurality of solar modules together. The plurality of splices provide away to make the connected modules mechanically rigid both duringtransport to the roof and after mounting for the lifetime of the system;provide wiring connections between modules; provide an electricalgrounding path for the modules; provide a way to add modules to thepanel; and provide a way to remove or change a defective module.Connector sockets are provided on the sides of the PV modules tosimplify the electrical assembly when the PV modules are connectedtogether with splices. However, the frame of the PV module is installedwith a groove to attach the mounting bracket and a hole to insert thesplice to connect the PV modules, which results in a labor-intensiveoperation. In addition, it requires one mounting bracket per PV moduleand multiple holes in the roof structure are required for installation,increasing the risk of leaks.

Another existing mounting system discloses a photovoltaic (PV) moduleframing and coupling system which enables the attachment of PV modulesto a roof or other mounting surface without requiring the use ofseparate structural support members. The system provides a parallelcoupling for securely interlocking the outside surfaces of parallelframe members together in a side-to-side arrangement to form an arraywith improved structural load distribution. The coupling member mayattach to a slot in the frame at substantially any position along thelength of the frame thereby enabling the interconnection of adjacent PVmodules along both an x and y-axis. The system may further provide arotating portion and locking portion for coupling to the frameattachment, mounting brackets for direct connection to a mountingsurface, grounding teeth for the automatic creation of a reliable twoaxis grounding matrix, and a rapid twist-lock engagement means forreliably interlocking and aligning PV modules in the array. However,this embodiment includes a side-to-side arrangement to form an array andan additional groove/slot is formed on the frame to engage couplingmember, which enables the interconnection of frames of adjacent PVmodules. In addition, the parallel couplings are extended beyond cornerregions of PV modules.

Various other mounting systems currently available are impossible toretrofit to existing roofs without cutting the shingles. The removal ofa single PV panel from the PV array installed using some of theseaforementioned mounting structures is difficult and can result inre-work thereby increasing labor and material costs. Some other systemsdo not allow for the capability to independently remove a single PVpanel without deconstructing an entire row of PV panels, whichsignificantly increases maintenance costs.

Therefore, there is a need for a rail-less roof mounting system thatwould provide a cost effective and improved means for PV moduleinstallations. Such a rail-less roof mounting system would provide anefficient means of installation that does not require any additionalmaterial or structure to support the rail-less roof mounting system.Such a rail-less roof mounting system would provide a corner-to-cornercoupling arrangement enabling the bridging of a PV module cornerdirectly with adjacent PV module corner. Such a needed device wouldprovide reduced shipping and hardware costs, labor and installation timeand cost; reduce the dead load on the roof structure along with designengineering costs; and hard and soft balance of system (BOS) cost. Thisrail-less roof mounting system would provide a single grounding lug anda single point of penetration with an elevated seal portion forwaterproofing the roof structure. Such a rail-less roof mounting systemwould typically be designed for implementation on composition shingleroofs, tile roofs, metal roofs, low slope roofs, or any roof that wouldbenefit from being waterproof. This mounting system would also providesimple grounding, wire management, and structural quality. This systemwould be simple, inexpensive, and lightweight. This system would providean improved engineering design to accommodate high snow and wind loads.Further, this rail-less roof mounting system would allow an installer toeasily work around roof obstructions like vents, skylights, and otherroof protrusions. This system would also minimize the number of partsand tools needed to assemble and install the PV module. This rail-lessroof mounting system would provide the ability to increase verticalleveling adjustability; to independently remove a single PV modulewithout deconstructing an entire row of the PV array; and allow for easymounting height adjustment after PV modules are installed. Finally, thisrail-less roof mounting system would require less manpower to installand rework.

SUMMARY OF THE DISCLOSURE

To minimize the limitations found in the prior art, and to minimizeother limitations that will be apparent upon the reading of thespecifications, preferred embodiment of the present invention provides arail-less roof mounting system for installing a plurality ofphotovoltaic (PV) modules on a roof structure. The rail-less roofmounting system comprises a base mount assembly attached to the roofstructure. The base mount assembly includes a base member having a topsurface and a bottom surface, a block slider having an elevated sealportion and a vertical engaging portion, and a top slider having a topportion and a bottom portion, and a clamp assembly having a clamp memberand a plate member.

The top surface of the base member is attached with a waterproof meansand the bottom surface of the base member is engaged with the roofstructure. The elevated seal portion, having a borehole formedtherethrough to receive the waterproof means, engages with the basemember and the roof structure, utilizing at least one tightening meansthat is inserted through the borehole. The vertical engaging portion hasa vertical groove along a surface thereof. The top slider having a trackwith a horizontal groove at the top portion and a sliding seal memberwith a sliding groove and a slot at the bottom portion. The sliding sealmember slides over the vertical engaging portion through the slidinggroove and secures, utilizing at least one fastening means that insertsthrough the vertical groove on the vertical engaging portion. The basemount assembly further includes a covering means that is adaptable tosecurely cover the at least one tightening means on the elevated sealportion for providing waterproof sealing between the base mount assemblyand the roof structure.

The clamp assembly comprises the clamp member that is coupled with theplate member. The clamp member includes a plurality of apertures on aninner surface thereof and a plurality of holes to receive a plurality ofscrews and the plate member that includes a plurality of slots. Theplurality of apertures and the plurality of slots are oriented along acommon longitudinal path to receive the at least one securing means. Theat least one securing means is slid through the horizontal groove andinserted through the plurality of slots on the plate member and theplurality of apertures on the inner surface of the clamp member. Thus,the clamp member, the plate member and the top slider are secured toeach other utilizing the at least one securing means. Thus, theplurality of PV modules are interlocked in a way to provide acorner-to-corner coupling arrangement which enables the connection of PVmodule corners to adjacent PV module corners by sandwiching above andbeneath the frame members of the PV modules.

A first objective of the present invention is to provide acorner-to-corner coupling arrangement, enabling the bridging of a PVmodule corner directly with adjacent PV module corner.

A second objective of the present invention is to provide an efficientmeans of installation that does not require any additional material orstructure to support the rail-less roof mounting system.

A third objective of the present invention is to provide acost-effective means for PV modules installation.

A fourth objective of the present invention is to provide a rail-lessroof mounting system that reduces dead load on a roof structure alongwith design engineering costs and hard and soft balance of system (BOS)costs.

A fifth objective of the present invention is to provide a rail-lessroof mounting system that is lightweight and to provide improvedengineering design to accommodate high snow and wind loads.

A sixth objective of the present invention is to provide a rail-lessroof mounting system that allows an installer to easily work around roofobstructions like vents, skylights, and other roof protrusions.

A seventh objective of the present invention is to provide a rail-lessroof mounting system that minimize the number of parts and tools neededto assemble and install the PV module.

An eighth objective of the present invention is to provide a rail-lessroof mounting system that provides the ability to increase verticalleveling adjustability.

A ninth objective of the present invention is to provide a rail-lessroof mounting system that independently removes a single PV modulewithout deconstructing an entire row of the PV array.

Another objective of the present invention is to provide a rail-lessroof mounting system that allows height adjustment of the rail-less roofmounting system after the installation of PV modules.

Yet another object of the present invention is to provide a rail-lessroof mounting system that has a single grounding lug and a single pointof penetration with an elevated seal portion for waterproofing the roofstructure.

Still yet another object of the present invention is to provide arail-less roof mounting system that retrofits into existing roofswithout the need to cut shingles.

Yet still another object of the present invention is to provide arail-less roof mounting system that eliminates the need to transport tothe jobsite, configure and cut long heavy rails for installationpurposes.

Still yet another object of the present invention is to provide arail-less roof mounting system that can cantilever PV modules inportrait orientation, landscape orientation or a combination of both.

Yet still another object of the present invention is to provide arail-less roof mounting system that employs a plurality of wire clips towork in multiple locations to minimize wire management issues.

These and other advantages and features of the present invention aredescribed with specificity so as to make the present inventionunderstandable to one of ordinary skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

Elements in the figures have not necessarily been drawn to scale inorder to enhance their clarity and improve understanding of thesevarious elements and embodiments of the invention. Furthermore, elementsthat are known to be common and well understood to those in the industryare not depicted in order to provide a clear view of the variousembodiments of the invention, thus the drawings are generalized in formin the interest of clarity and conciseness.

FIG. 1 illustrates a perspective view of a rail-less roof mountingsystem for installing a plurality of photovoltaic (PV) modules on a roofstructure in accordance with the preferred embodiment of the presentinvention;

FIG. 2 illustrates an exploded view of a base mount assembly inaccordance with the preferred embodiment of the present invention;

FIG. 3 illustrates an exploded view of a clamp assembly associated withthe base mount assembly in accordance with the preferred embodiment ofthe present invention;

FIG. 4 illustrates a first mounting position of the rail-less roofmounting system interlocking the plurality of PV modules to form acorner-to-corner coupling arrangement in accordance with the preferredembodiment of the present invention;

FIG. 5 illustrates a second mounting position of the rail-less roofmounting system interlocking the plurality of PV modules to form thecorner-to-corner coupling arrangement in accordance with the preferredembodiment of the present invention;

FIG. 6 illustrates the rail-less roof mounting system interlocking twoPV modules in an arrangement in accordance with an alternateconfiguration of the present invention;

FIG. 7 illustrates installation of the rail-less roof mounting system onthe roof structure in accordance with the preferred embodiment of thepresent invention;

FIG. 8 illustrates the base mount assembly configured to adjust mountingheight of the rail-less roof mounting system in accordance with thepreferred embodiment of the present invention;

FIG. 9 illustrates a perspective view of a PV array skirt providing asnap-fit engagement with the rail-less roof mounting system inaccordance with the preferred embodiment of the present invention;

FIG. 10 illustrates a profile view of the PV array skirt providing thesnap-fit engagement with the rail-less roof mounting system shown inFIG. 9;

FIG. 11 illustrates one embodiment of a clamp assembly in accordancewith the present invention

FIG. 12 illustrates one embodiment of a clamp assembly in accordancewith the present invention; and

FIG. 13 illustrates an alternative embodiment of a clamp assembly inaccordance with the present invention.

DETAILED DESRIPTION OF THE DRAWINGS

In the following discussion that addresses a number of embodiments andapplications of the present invention, reference is made to theaccompanying drawings that form a part hereof, and in which is shown byway of illustration specific embodiments in which the invention may bepracticed. It is to be understood that other embodiments may be utilizedand changes may be made without departing from the scope of the presentinvention.

Various inventive features are described below that can each be usedindependently of one another or in combination with other features.However, any single inventive feature may not address any of theproblems discussed above or only address one of the problems discussedabove. Further, one or more of the problems discussed above may not befully addressed by any of the features described below.

Turning now to FIG. 1, a perspective view of a rail-less roof mountingsystem 100 for installing a plurality of photovoltaic (PV) modules 170,172, 174 (See FIG. 4) on a roof structure 176 (See FIG. 7) in accordancewith the preferred embodiment of the present invention is illustrated.The rail-less roof mounting system 100 comprises a base mount assembly102 that is associated with a clamp assembly 144 to bridge the pluralityof PV modules 170, 172, 174 and to install the plurality of PV modules170, 172, 174 on the roof structure 176. The base mount assembly 102attached to the roof structure 176 comprises a base member 104 having atop surface 108 and a bottom surface (not shown), a block slider 110having an elevated seal portion 112 (See FIG. 2) and a vertical engagingportion 114 and a top slider 124 having a top portion 126 and a bottomportion 128.

The clamp assembly 144 includes a clamp member 146 that is fixed with aplate member 148. The rail-less roof mounting system 100 can be easilydisassembled and hence provides a compact means of storage when not inuse. The bottom surface (not shown) of the base member 102 is engagedwith the roof structure 176. The block slider 110 is connected with thebase member 104 and with the bottom portion 128 of the top slider 124. Atrack 130 having a horizontal groove 132 is included at the top portion126 of the top slider 124 and a sliding seal member 134 having a slidinggroove 136 and a slot 138 are included at the bottom portion 128 of thetop slider 124. The sliding seal member 134 is secured to the blockslider 110 utilizing at least one fastening means 140. The clamp member146 and the plate member 148 are attached with the track 130 utilizingat least one securing means 150. The clamp member 146 includes aplurality of apertures 154 (See FIG. 10) on an inner surface 156 thereofand a plurality of holes 157 to receive a plurality of screws 178. Theplate member 148 includes a plurality of slots 152 to receive the atleast one securing means 150.

FIG. 2 illustrates an exploded view of the base mount assembly 102 inaccordance with the preferred embodiment of the present invention. Awaterproof means 106 is attached on the top surface 108 of the basemember 104. In the preferred embodiment, the base member 104 is madefrom an aluminum flashing. The bottom surface (not shown) of the basemember 104 is engaged with the roof structure 176. The elevated sealportion 112, having a borehole 116 formed therethrough to receive thewaterproof means 106, engages with the base member 104 and the roofstructure 176, utilizing at least one tightening means 118 that isinserted through the borehole 116 and the waterproof means 106. Then,the at least one tightening means 118 comes from the borehole 116 andthe waterproof means 106 is drilled into the roof structure 176. Thebase mount assembly 102 includes a covering means 142 that is adaptableto securely cover the at least one tightening means 118 on the elevatedseal portion 112 for providing waterproof sealing between the base mountassembly 102 and the roof structure 176.

The at least one tightening means 118 is of the type typically known inconstruction/installation and may comprise a structural screw.Specifically, the at least one tightening means 118 is a T-30/hex washerhead lag screw. A sealing washer 158 is utilized for fitting on the atleast one tightening means 118 and adapted to seal the borehole 116 inthe elevated seal portion 112, through which the at least one tighteningmeans 118 is fitted, so as to prevent seepage of water. Preferably, thesealing washer 158 is an annular disc, which is deformable to create atight seal. In one embodiment, the sealing washer 158 comprises a diskof rigid material such as steel, with a section or outer layer ofdeformable material that may be selected from a group consisting of:fluorinated silicone, polyurethane and rubber. Additionally, the sealingwasher 158, which is most likely to experience wear, is a simple,inexpensive part that can be replaced individually, as needed.

The vertical engaging portion 114 of the block slider 110 has a verticalgroove 120 along the surface 122 thereof. The sliding seal member 134 ofthe top slider 124 slides over the vertical engaging portion 114 throughthe sliding groove 136 on the top slider 124 and secures to the blockslider 110, utilizing the at least one fastening means 140 that isinserted through the vertical groove 120 on the vertical engagingportion 114 and the slot 138 on the sliding seal member 134. Preferably,the at least one fastening means 140 can be in the form of, for example,a cap screw or similar structures. The at least one fastening means 140is securely tightened utilizing a lock nut 162. Typically, the lock nutis a serrated flange hex nut. The base mount assembly 102 furtherincludes a plurality of wire clips 163 for holding/retaining one or morewires (not shown) from/for each PV module 170, 172, 174 that is mountedto a building surface by the clamp member 146.

FIG. 3 illustrates an exploded view of the clamp assembly 144 associatedwith the base mount assembly 102 in accordance with the preferredembodiment of the present invention. The clamp assembly 144 comprisesthe clamp member 146 that is coupled with the plate member 148. Theclamp member 146 includes a plurality of apertures 154 (See FIG. 10) onan inner surface 156 thereof and a plurality of holes 157 to receive aplurality of screws 178, and the plate member 148 includes a pluralityof slots 152. The plurality of apertures 154 and the plurality of slots152 are oriented along a common longitudinal path to receive the atleast one securing means 150.

The clamp assembly 144 is assembled with the base mount assembly 102when in use. The at least one securing means 150 is slid through thehorizontal groove 132 and inserted through the plurality of slots 152 onthe plate member 148 and the plurality of apertures 154 on the innersurface 156 of the clamp member 146. Thus, the clamp member 146, theplate member 148 and the top slider 124 are secured to each otherutilizing the at least one securing means 150. The at least one securingmeans 150 may comprise a cap screw. Preferably, the at least onesecuring means 150 is a stainless steel 5/16 “Ø×2” grade 18/8 machinebolt. While securing the clamp assembly 144 with the base mount assembly102, an engaging nut 160 and a plurality of retainer rings 161 areutilized with the at least one securing means 150 to provide a tightseal. Preferably, the plurality of retainer rings 161 is made of plasticand the engaging nut 160 is a hex nut. It is noted that the engaging nut160 utilized with the at least one securing means 150 replaces theconventional brake and provides a tight, secure attachment between theclamp assembly 144 and the base mount assembly 102. The least onesecuring means 150 is securely tightened utilizing the lock nut 162.Specifically, the lock nut 162 is a serrated flange hex nut.

The clamp member 146 replaces the conventional brake and eliminates edgebridge/mid edge conflict. This clamp assembly 144 works both on top ofthe base mount assembly 102 as well as independently. Such clampassembly 144 is adjustable to fit “off-the-shelf” available PV modules.Moreover, the clamp assembly 144 is adjustable to mount most standardsize PV modules. Furthermore, the clamp assembly 144 can fit all typesof framed and frameless PV modules.

FIG. 4 illustrates a first mounting position of the rail-less roofmounting system 100 interlocking the plurality of PV modules 170, 172,174 to form a corner-to-corner coupling arrangement in accordance withthe preferred embodiment of the present invention. The clamp member 146interconnects the frame member 164 of the PV module 170 to the framemember 166 of the adjacent PV module 172. The clamp member 146 isattached to the frame members 164, 166, 168 of the plurality of PVmodules 170, 172, 174 by inserting a plurality of screws 178 into theplurality of holes 157 at a middle of a formed PV array. In the firstmounting position, the clamp assembly 144 is coupled with the base mountassembly 102, utilizing one of the securing means 150 that is insertedthrough one of the apertures 154 in the inner surface 156 of the clampmember 146 and one of the slots 152 on the plate member 148.

FIG. 5 illustrates a second mounting position of the rail-less roofmounting system 100 interlocking the plurality of PV modules 170, 172,174 to form the corner-to-corner coupling arrangement in accordance withthe preferred embodiment of the present invention. The clamp member 146interconnects the frame member 164 of the PV module 170 to the framemember 166 of the adjacent PV module 172. In the second mountingposition, the clamp assembly 144 is coupled with the base mount assembly102 utilizing another securing means 150 that is inserted throughanother aperture 154 in the inner surface 156 of the clamp member 146and another slot 152 on the plate member 148.

For instance, the clamp member 146 interlocks corners of the framemembers 164, 166, 168 of the plurality of PV modules 170, 172, 174 toform a corner-to-corner coupling arrangement as illustrated in FIGS. 4and 5. Although the rail-less roof mounting system 100 is shown in FIGS.4 and 5 holding three PV modules 170, 172, 174, it is noted that the atleast one rail-less roof mounting system 100 can bridge four PV modulesat the corners in any row and column configuration. Thus, the pluralityof PV modules 170, 172, 174 are interlocked in a way to provide thecorner-to-corner coupling arrangement which enables the connection of PVmodule corners to adjacent PV module corners by sandwiching above andbeneath the frame members 164, 166, 168 of the plurality of PV modules170, 172, 174. Moreover, the clamp member 146 interlocks top and bottomsurfaces of the frame members 164, 166, 168 of the plurality of PVmodules 170, 172, 174 as shown in FIGS. 4 and 5.

In the preferred embodiment, the plurality of PV modules 170, 172, 174provided is aluminum framed PV modules. However, while the presentinvention will be described for use with a framed PV module, the presentinvention is not so limited. Thus, it is within the scope of the presentinvention that rigid frameless PV modules, i.e. PV modules utilizingglass modules, may also be utilized to practice the present invention.In one embodiment, the corner-to corner coupling arrangement providesconnection with other mounting and/or racking components and does notprovide attachment or connection with any portion of the roof structure176 such as waterproofing layers, structural rooftop layers or any/allcosmetic layers.

FIG. 6 illustrates the rail-less roof mounting system 100 interlockingtwo PV modules 192, 194 in accordance with an alternate configuration ofthe present invention. In this configuration, the rail-less roofmounting system 100 interlocks top and bottom surfaces of frame membersof two adjacent PV modules 192, 194 at an end of a formed PV array.

FIG. 7 illustrates installation of the rail-less roof mounting system100 on the roof structure 176 in accordance with the preferredembodiment of the present invention. The roof structure 176 serves as amounting surface for the base mount assembly 102. The base member 104 isplaced on the roof structure 176 and the at least one tightening means118 is inserted through the borehole 116, the waterproof means 106 and aroof rafter 180 that is positioned just beneath a roofing material 182and a roofing sheathing 184. The illustrative installation provides asingle point of penetration with the elevated seal portion 112 forproviding waterproofing. A minimum embedment depth of 2½ inches ispreferred. Typically, the at least one tightening means 118 is a GRK RSSrugged structural screw made of specially hardened steel to provide withhigh tensile, torque and shear strength. For example, the screw has a5/16 inch nominal diameter underneath the sealing washer 158, a minimumof torque screw to 13 ft-lb and may be made of hardened steel preferablywith an all weather coating such as Climatek™ coating. Furthermore, theroof structure 176 can include pre-stamped and/or pre-drilled pilotholes formed therein through which the at least one tightening means 118can be inserted. For example, the pilot holes have a diameter of about ⅛of an inch. More profitably, the rail-less roof mounting system 100 iseasily and quickly installed with minimal tools, such as a ½ inchopen-end box wrench and a ½ inch socket.

A method for installing a plurality of photovoltaic (PV) modules 170,172, 174 on a roof structure 176 includes the following steps. Firstly,a rail-less roof mounting system 100 is provided for mounting theplurality of PV modules 170, 172, 174. The base member 104 is placed onthe roof structure 176 and the block slider 110 is positioned above thebase member 104 by inserting the waterproof means 106 through theborehole 116 on the elevated seal portion 112. The at least onetightening means 118 is inserted through the borehole 116 and thewaterproof means 106 to secure the block slider 110 and the base member104 with the roof structure 176. The sliding seal member 134 is slidover the vertical engaging portion 114 through the sliding groove 136 onthe top slider 124. The at least one fastening means 140 is insertedthrough the vertical groove 120 on the vertical engaging portion 114 andthe slot 138 on the top slider 124 to attach the top slider 124 to theblock slider 110. The at least one fastening means 140 is tightenedutilizing the lock nut 162. The at least one securing means 150 is slidthrough the horizontal groove 132 and inserted through the plurality ofslots 152 on the plate member 148 and a plurality of apertures 154 onclamp member 146 to attach the clamp member 146 and the plate member 148with the track 130 of the top slider 124. The at least one securingmeans 150 is tightened utilizing the lock nut 162.

Then, the clamp member 146 interconnects the frame member 164 of the PVmodule 170 to the frame member 166 of the adjacent PV module 172 toprovide a corner-to-corner coupling arrangement. Finally, the clampmember 146 is attached with the frame member 164 of the PV module 170 byinserting a plurality of screws 178 into a plurality of holes 157 on theclamp member 146. Thus, the corner-to-corner coupling arrangementenables the connection of PV module corners to adjacent PV modulecorners by sandwiching above and beneath the frame members 164, 166, 168of the plurality of PV modules 170, 172, 174.

FIG. 8 illustrates the base mount assembly 102 configured to adjust themounting height of the rail-less roof mounting system 100 in accordancewith the preferred embodiment of the present invention. The height ofmounting of the rail-less roof mounting system 100 is adjusted byadjusting the position of the top slider 124 along the vertical engagingportion 114 of the block slider 110. The top slider 124 can be movedalong the vertical engaging portion 114 and can be secured at desiredposition or height by tightening the at least one fastening means 140through the vertical groove 120 on the vertical engaging portion 114 andthe slot 138 on the sliding seal member 134.

FIGS. 9 and 10 illustrate perspective and profile views of a PV arrayskirt 186 providing a snap-fit engagement with the rail-less roofmounting system 100 in accordance with the preferred embodiment of thepresent invention. A PV array skirt 186 is installed on an edge of a PVarray. The PV array skirt 186 may provide improved aesthetics, safetyand structural performance. The PV array skirt 186 may partially orfully obscure air gap and mounting hardware located beneath the PVarray. The PV array skirt 186 may allow for the snap-fit engagement ofthe PV array skirt 186 to the rail-less roof mounting system 100. Therail-less roof mounting system 100 may also allow for the snap-fitengagement with the plurality of PV modules 170, 172, 174. The snap-fitengagement between the PV array skirt 186 and the rail-less roofmounting system 100 is achieved by inserting an extrusion 188 of the PVarray skirt 186 along a grooved edge 147 of the plate member 148. Thus,the grooved edge 147 provides a seat for the extrusion 188 of the PVarray skirt 186 to provide the snap-fit engagement. The snap-fitengagement provides a longer landing ability to the plate member 148 andan ability to easily clean out debris from under the PV array skirt 186.

FIG. 11 illustrates a perspective view of interlocking of two PV arrayskirts 186 in accordance with the preferred embodiment of the presentinvention. The two PV array skirts 186 are placed end-to-end and readyto be interlocked together with a plurality of skirt clips 190. Theplurality of skirt clips 190 is adaptable to prevent the PV array skirt186 from sagging. The PV array skirt 186 may be manufactured from bentmetal and may snap onto the rail-less roof mounting system 100 via thegrooved edge 147 of the plate member 148. The rail-less roof mountingsystem 100 allows for vertical height adjustment therefore allowing foradjustment of height of the PV array skirt 186 above the roof structure176 thus preventing the debris from entering the underlying air gap. Agap provided between the PV array skirt 186 and the frame member 164 maybe sized in order to enable adequate room for installing the pluralityof wire clips 163 or any other mounting structures.

The embodiments discussed above allow for portrait orientation,landscape orientation or a combination of both. In a portraitorientation, the PV array having each of the plurality of PV modules170, 172, 174 oriented, with the longest axis of the plurality of PVmodules 170, 172, 174 extend in a forward-rearward direction, which istypically the south-north direction. The plurality of PV modules 170,172, 174 have long edges with length running in cross-slope direction.It is noted, however, that the plurality of PV modules 170, 172, 174 canalternatively be oriented in a landscape orientation, that is, with thelongest axis of the plurality of PV modules 170, 172, 174 extending in alateral or side-to-side direction which is typically the east-westdirection. Thus, the above-disclosed rail-less roof mounting system 100can be used for gable roofs, hip roofs and flat and low slope gableroofs. The plurality of PV modules 170, 172, 174 have short edges withwidth running in cross-slope direction. Further, the rail-less roofmounting system 100 has the ability to cantilever the plurality of PVmodules 170, 172, 174 for both portrait and landscape orientation, forexample, 13 inch cantilever portrait and 19 inch cantilever landscape.

The preferred embodiment reduces the number of parts, the size, and thecost of the parts, resulting in a total part count of approximately 151(a 50% reduction) and a total mounting system hardware cost of $0.30/Wretail (a 54% reduction). Further, the labor time to install therail-less roof mounting system 100 is decreased by a minimum of 35%,which results in the reduction of installation times by over 55% asinstallation efficiencies grow. When the rail-less roof mounting system100 is installed for bridging the plurality of PV modules 170, 172, 174,it is revealed a decrease of around 47% in non-electrical installationhours. Additional system design and procurement soft-costs are reducedby 67%, when utilizing the system.

FIG. 12 illustrates one embodiment of a clamp assembly 196 in accordancewith the present invention. The clamp assembly 196 is small in size andadaptable to use for end-clamping the plurality of PV modules 170, 172,174. The clamp assembly 196 includes a clamp member 198 and a platemember 200. The clamp member 198 includes an aperture (not shown) on aninner surface 202 thereof and a pair of holes (not shown) to receive apair of screws 204 and the plate member 200 includes a slot (not shown).The plate member 200 further includes a grooved edge 206 to accommodatethe PV array skirt 186. At least one securing means 208 is insertedthrough the aperture (not shown) of the clamp member 198 and the slot(not shown) of the plate member 200 to engage the clamp member 198 andthe plate member 200.

The presently disclosed system is advantageous because it provides thecorner-to-corner coupling arrangement, enabling the bridging of cornersof the plurality of PV modules 170, 172, 174. The rail-less roofmounting system 100 provides a single grounding lug 175 for assemblingthe PV array consisting of 300 PV modules or less. Further, therail-less roof mounting system 100 includes the plurality of wire clips163, which are designed to work in multiple locations to minimize wiremanagement issues. The rail-less roof mounting system 100 allows formore customizability in the PV array shape by allowing the installer toeasily work around roof obstructions like vents, skylights, and otherroof protrusions This rail-less roof mounting system 100 provides theability to increase vertical leveling adjustability, for instance, 3inch to 5 inch. The rail-less roof mounting system 100 has the abilityto independently remove a single PV module without deconstructing anentire row of the PV array and allow for easy mounting height adjustmentafter the plurality of PV modules 170, 172, 174 are installed. Therail-less roof mounting system 100 can be easily assembled anddisassembled and the components can be laid flat for easy storage andshipping. Furthermore, the rail-less roof mounting system 100 wouldrequire less manpower to install and rework.

The foregoing description of the preferred embodiment of the presentinvention has been presented for the purpose of illustration anddescription. It is not intended to be exhaustive or to limit theinvention to the precise form disclosed. Many modifications andvariations are possible in light of the above teachings. It is intendedthat the scope of the present invention to not be limited by thisdetailed description, but by the claims and the equivalents to theclaims appended hereto.

What is claimed is:
 1. A rail-less roof mounting system for installing a plurality of photovoltaic (PV) modules on a roof structure, the rail-less roof mounting system comprising: a. a clamp assembly having a clamp member attached to a track utilizing at least one bolt and wherein the clamp member interlocks a top and bottom surface of a frame member of a PV module to an adjacent frame member top and bottom surface to provide a corner-to-corner coupling arrangement; b. whereby the clamp assembly is configured to interlock the plurality of PV modules by connecting a first PV module corner to an adjacent PV module corner by sandwiching above and beneath frame members of the plurality of PV modules; c. wherein the clamp assembly is elevated entirely above said roof structure without any load bearing connection between the clamp assembly and the roof structure other than through the respective frames of the PV modules; and d. a mount attached to the roof structure, a second clamp assembly attached to the mount and connected to the frame member of at least one PV module remote from the corner.
 2. The rail-less roof mounting system of claim 1 wherein the clamp member and a plate member are attached to the track utilizing at least one bolt that is positioned within a horizontal groove at the top portion and inserted through a plurality of apertures and a plurality of slots on said clamp member.
 3. The rail-less roof mounting system of claim 1 further comprising plurality of wire clips for holding/retaining one or more wires from/for each PV module that is mounted to a building surface by the clamp assembly.
 4. The rail-less roof mounting system of claim 1 further comprising a single grounding lug grounding the PV array consisting of 300 PV modules or fewer.
 5. A method for installing a plurality of photovoltaic (PV) modules on a roof structure, the method comprising the steps of: a. providing a clamp assembly including a clamp member; b. attaching the clamp member to the PV modules; c. interconnecting to said clamp assembly a PV module frame member to an adjacent PV module frame member to provide a corner-to-corner coupling arrangement; d. whereby the corner-to-corner coupling arrangement enables the connection of PV module corners to adjacent PV module corners by sandwiching above and beneath frame members of the plurality of PV modules; e. wherein the clamp assembly is elevated entirely above said roof structure without any load bearing connection between the clamp assembly and the roof structure other than through the respective frames of the PV modules; and f. attaching a PV support member to said roof structure remote from the corners and attaching said first PV module to said PV support member.
 6. The method for installing a plurality of photovoltaic (PV) modules on a roof structure of claim 5 further comprising grounding through a single grounding lug for assembling the PV array consisting of 300 PV modules or fewer.
 7. The method for installing a plurality of photovoltaic (PV) modules on a roof structure of claim 6 wherein said grounding occurs through said clamp assembly.
 8. The method for installing a plurality of photovoltaic (PV) modules on a roof structure of claim 5 further comprising adjusting a top slider along a vertical engaging portion to thereby adjust vertical leveling by between 3 inches and 5 inches.
 9. A rail-less roof mounting system for installing a plurality of photovoltaic (PV) modules on a roof structure, the rail-less roof mounting system comprising: a. a flashing assembly attached to the roof structure comprising: i. a base member having a top surface and a bottom surface, the bottom surface being engaged with the roof structure, the base member including an upstanding sleeve; ii. an elevated seal portion and a vertical engaging portion, the elevated seal portion having a borehole formed therethrough to receive the upstanding sleeve; iii. a top slider having a top portion with a horizontal slot and a bottom portion having a sliding member; and iv. a clamp assembly attached to the flashing assembly having a clamp member interlocking a frame member of a PV module to a frame member of an adjacent PV module by sandwiching above and beneath frame members of the plurality of PV modules; b. whereby the plurality of PV modules are interlocked in a way to provide a corner-to-corner coupling arrangement which enables the connection of PV module corners to adjacent PV module corners by sandwiching above and beneath frame members of the plurality of PV modules; and c. wherein the clamp assembly is elevated entirely above said roof structure without any load bearing connection between the clamp assembly and the roof structure other than through the respective frames of the PV modules.
 10. The rail-less roof mounting system of claim 9 wherein the base member is attached to the roof structure utilizing at least one screw that is inserted through the borehole on the elevated seal portion.
 11. The rail-less roof mounting system of claim 9 wherein the sliding member is adapted to slide over the vertical engaging portion along the sliding groove and secured utilizing at least one fastener that is inserted through a vertical engaging portion vertical slot and a bottom portion vertical slot of the top slider.
 12. The rail-less roof mounting system of claim 9 wherein the flashing assembly includes a cover that is adaptable to cover the at least one screw on the elevated seal portion for providing waterproof sealing between the flashing assembly and the roof structure.
 13. The rail-less roof mounting system of claim 9 wherein the clamp member and a plate member are attached to a track utilizing at least one bolt that is positioned within a horizontal groove at the top portion and inserted through a plurality of apertures and a plurality of slots on said clamp member.
 14. The rail-less roof mounting system of claim 9 wherein the base member is made from an aluminum flashing.
 15. The rail-less roof mounting system of claim 9 wherein the base mount assembly includes a plurality of wire clips for holding/retaining one or more wires from/for each PV module that is mounted to a building surface by the clamp assembly.
 16. The rail-less roof mounting system of claim 9 wherein a mounting height of the rail-less roof mounting system is adjustable through adjustment of the position of the top slider along the vertical engaging portion.
 17. The rail-less roof mounting system of claim 9 allows a snap-fit engagement to provide a longer landing ability to a plate member when installing the rail-less roof mounting system with a PV array skirt.
 18. The rail-less roof mounting system of claim 9 further comprising a single grounding lug grounding the PV array consisting of 300 PV modules or fewer.
 19. The rail-less roof mounting system of claim 18 wherein said single grounding lug grounds the PV array through said clamp assembly.
 20. The rail-less roof mounting system of claim 9 wherein the clamp member is attached with the frame members of the plurality of PV modules by inserting a plurality of screws into a plurality of holes on the clamp member. 